U.S. patent application number 15/910116 was filed with the patent office on 2018-09-06 for cuff support.
This patent application is currently assigned to TOYOTA JIDOSHA KABUSHIKI KAISHA. The applicant listed for this patent is TOYOTA JIDOSHA KABUSHIKI KAISHA. Invention is credited to Hiroshi HOSHINA, Shotaro OKAMOTO.
Application Number | 20180254674 15/910116 |
Document ID | / |
Family ID | 63355394 |
Filed Date | 2018-09-06 |
United States Patent
Application |
20180254674 |
Kind Code |
A1 |
HOSHINA; Hiroshi ; et
al. |
September 6, 2018 |
CUFF SUPPORT
Abstract
A cuff support attached to an axial end surface of a stator core
including an annular yoke, a plurality of teeth, and a plurality of
slots formed between the teeth includes: an annular plate making
contact with the yoke; a plurality of ribs projecting toward an
inner peripheral side of the annular plate so as to correspond to
the teeth; and a plurality of spaces formed between the ribs so as
to correspond to the slots. The cuff support is made of an elastic
member. The ribs are being apart from the axial end surface of the
stator core from roots of the ribs toward tip ends of the ribs.
When a coil is wound around the teeth and the ribs so as to pass
through the slots and the spaces, the ribs are brought into
pressure contact with the coil due to an elastic force.
Inventors: |
HOSHINA; Hiroshi;
(Toyota-shi, JP) ; OKAMOTO; Shotaro; (Nagoya-shi,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TOYOTA JIDOSHA KABUSHIKI KAISHA |
Toyota-shi |
|
JP |
|
|
Assignee: |
TOYOTA JIDOSHA KABUSHIKI
KAISHA
Toyota-shi
JP
|
Family ID: |
63355394 |
Appl. No.: |
15/910116 |
Filed: |
March 2, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02K 1/185 20130101;
H02K 3/12 20130101; H02K 3/50 20130101; H02K 1/16 20130101 |
International
Class: |
H02K 1/18 20060101
H02K001/18; H02K 1/16 20060101 H02K001/16; H02K 3/12 20060101
H02K003/12 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 3, 2017 |
JP |
2017-040362 |
Claims
1. A cuff support attached to an axial end surface of a stator core
including an annular yoke, a plurality of teeth projecting toward
an inner peripheral side of the yoke, and a plurality of slots
formed between the teeth, the cuff support comprising: an annular
plate making contact with the yoke; a plurality of ribs projecting
toward an inner peripheral side of the annular plate so as to
correspond to the teeth; and a plurality of spaces formed between
the ribs so as to correspond to the slots, wherein the cuff support
is made of an elastic member, the ribs are being apart from the
axial end surface of the stator core from roots of the ribs toward
tip ends of the ribs, and when a coil is wound around the teeth and
the ribs so as to pass through the slots and the spaces, the ribs
are brought into pressure contact with the coil due to an elastic
force.
2. The cuff support according to claim 1, wherein the ribs are
warped from the roots to the tip ends so as to be apart from the
axial end surface of the stator core.
3. The cuff support according to claim 1, wherein a gap between the
ribs and the axial end surface of the stator core increases from
the roots toward the tip ends.
4. The cuff support according to claim 1, further comprising a
cylindrical flange configured to connect the tip ends of the ribs
to each other, the flange extending from the tip ends of the ribs
toward an opposite side to the stator core.
Description
INCORPORATION BY REFERENCE
[0001] The disclosure of Japanese Patent Application No.
2017-040362 filed on Mar. 3, 2017 including the specification,
drawings and abstract is incorporated herein by reference in its
entirety.
BACKGROUND
1. Technical Field
[0002] The present disclosure relates to a structure of a cuff
support attached to an axial end surface of a stator core for a
rotary electric machine.
2. Description of Related Art
[0003] A rotor electric machine often uses a distributed-winding
coil in which a conductor wire is wound over a plurality of teeth
such that the conductor wire is passed through a slot of a stator
core from a first side and the conductor wire projecting from a
second side is bent in a circumferential direction and then passed
through another slot distanced from the above slot. In recent
years, there has been used a method for forming a
distributed-winding coil such that: a conductor segment formed by
shaping a flat wire in a U-shape is used as a conductor wire; a
linear part of the conductor segment is inserted into a slot from a
first axial end surface of a stator core; and the linear part
projecting from a second axial end surface of the stator core is
bent in a circumferential direction and welded with a flat wire
projecting from another slot (e.g., see Japanese Patent Application
Publication No. 2016-32392 (JP 2016-32392 A)).
[0004] In this method, the insertion of the conductor segment, the
bending of the linear part, and the welding are performed such that
insulating members, made of resin and called a cuff support, are
attached to axial end surfaces of the stator core. The cuff support
is an annular member including ribs corresponding to teeth of the
stator core and openings corresponding to slots of the stator core.
The conductor segment constituting the coil is inserted into a slot
from a firs side of the stator core, and the linear part of the
conductor segment, projecting from an opening of the cuff support
on a second side is bent in the circumferential direction on an
upper side relative to a rib of the cuff support. When the coil is
formed by bending and welding of the linear parts of the conductor
segments, the coil and the cuff support are impregnated with
varnish, so that the coil and the cuff support are fixed.
SUMMARY
[0005] Due to variability in bending shape at the time when the
linear parts of the conductor segments are bent, a gap might be
formed between bent parts of the conductor segments and the upper
side of the cuff support. In this case, adhesion between the coil
and the cuff support becomes insufficient, thereby resulting in
that fixation between the coil and the cuff support with the
varnish might be insufficient.
[0006] In view of this, the present disclosure provides a cuff
support that improves an adhesion property with a coil.
[0007] A cuff support of an aspect of the present disclosure is a
cuff support attached to an axial end surface of a stator core
including an annular yoke, a plurality of teeth projecting toward
an inner peripheral side of the yoke, and a plurality of slots
formed between the teeth, and includes an annular plate making
contact with the yoke, a plurality of ribs projecting toward an
inner peripheral side of the annular plate so as to correspond to
the teeth, and a plurality of spaces formed between the ribs so as
to correspond to the slots. The cuff support is made of an elastic
member. The ribs are being apart from the axial end surface of the
stator core from roots of the ribs toward tip ends of the ribs.
When a coil is wound around the teeth and the ribs so as to pass
through the slots and the spaces, the ribs are brought into
pressure contact with the coil due to an elastic force.
[0008] With this configuration, it is possible to improve an
adhesion property between the coil and the cuff support.
[0009] The cuff support of the aspect of the present disclosure may
include a cylindrical flange configured to connect the tip ends of
the ribs to each other, and the flange may extend from the tip ends
of the ribs toward an opposite side to the stator core.
[0010] Due to variability in bending shape at the time when linear
parts of conductor segments are bent, bent parts of the conductor
segments might protrude toward an inner peripheral side of the
stator core, so that the coil approaches a rotor to increase a
loss. However, the above configuration makes it possible to
restrain the coil from protruding toward the inner peripheral side
of the stator core.
[0011] The aspect of the present disclosure makes it possible to
improve an adhesion property between the coil and the cuff
support.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Features, advantages, and technical and industrial
significance of exemplary embodiments of the disclosure will be
described below with reference to the accompanying drawings, in
which like numerals denote like elements, and wherein:
[0013] FIG. 1 is a perspective view illustrating a stator for a
rotary electric machine using a cuff support according to an
embodiment of the present disclosure;
[0014] FIG. 2 is an exploded perspective view illustrating a
structure of the stator illustrated in FIG. 1;
[0015] FIG. 3 is a perspective view illustrating a state where the
cuff support of the embodiment of the present disclosure is placed
on an axial end surface of a stator core;
[0016] FIG. 4 is a sectional view illustrating a state where the
cuff support of the embodiment of the present disclosure is placed
on the axial end surface of the stator core;
[0017] FIG. 5 is a circumferential developed sectional view (a A-A
section illustrated in FIG. 4) illustrating a state where linear
parts of conductor segments projecting from the cuff support are
bent in a circumferential direction in a state illustrated in FIGS.
3, 4;
[0018] FIG. 6 is a sectional view illustrating the cuff support,
the stator core, and bent parts in a state where the linear parts
of the conductor segments are bent to form a coil as illustrated in
FIG. 5;
[0019] FIG. 7 is a perspective view illustrating a state where a
cuff support of another embodiment of the present disclosure is
placed on an axial end surface of a stator core;
[0020] FIG. 8 is a sectional view illustrating bent parts in a
state where linear parts of conductor segments are bent to form a
coil, and the cuff support and the stator core in another
embodiment; and
[0021] FIG. 9 is a perspective view of a stator for a rotary
electric machine using the cuff support according to another
embodiment of the present disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
[0022] With reference to the drawings, the following describes an
embodiment of the present disclosure. First described is a stator
10 for a rotary electric machine constituted by use of a cuff
support 40 of the present embodiment. As illustrated in FIG. 1, the
stator 10 is constituted by a stator core 20, the cuff supports 40
attached to axial end surfaces 20a, 20b of the stator core 20, and
a coil 30 wound around the stator core 20 and the cuff supports 40.
Respective coil ends 35, 36 project axially outward from the axial
end surfaces 20a, 20b of the stator core 20. Note that, since input
and output terminals (not shown) of the coil 30 are attached to a
coil-end-35 side of the stator 10 illustrated in FIG. 1, the
coil-end-35 side of the stator 10 is referred to as a lead side and
a coil-end-36 thereof is referred to as an opposite-to-lead side in
the following description.
[0023] As illustrated in FIG. 2, the stator core 20 is configured
such that a plurality of electromagnetic steel sheets is laminated.
The stator core 20 includes an annular yoke 21 extending along a
circumferential direction of the stator 10, and a plurality of
teeth 22 projecting toward a radially inner side of the stator 10
from an inner peripheral surface of the yoke 21. The plurality of
teeth 22 is placed at regular intervals in the circumferential
direction of the stator 10. A slot 23 is formed between the teeth
22 adjacent to each other in the circumferential direction of the
stator 10. A plurality of slots 23 is placed at regular intervals
in the circumferential direction of the stator. The teeth 22 and
the slots 23 extend along an axial direction.
[0024] The cuff support 40 is attached to the axial end surface 20a
on the lead side of the stator core 20. The cuff support 40 is an
insulating resin molding member, and is made of epoxy resin, for
example.
[0025] As illustrated in FIG. 3, the cuff support 40 includes an
annular plate 41 making contact with the yoke 21, a plurality of
ribs 43 projecting toward an inner peripheral side of the annular
plate 41 so as to correspond to the teeth 22, and a plurality of
spaces 44 formed between the ribs 43 so as to correspond to the
slots 23. The ribs 43 are formed in a comb shape in which
respective roots 43a are connected to the annular plate 41 and
respective tip ends 43b are apart from each other. The ribs 43 of
the cuff support 40 are warped from the roots 43a toward the tip
ends 43b so as to be apart axially outward from the axial end
surface 20a of the stator core 20.
[0026] As illustrated in FIG. 2, the coil 30 is constituted by a
plurality of conductor segments 31 inserted into all the slots 23
in the circumferential direction of the stator core 20. Note that
FIG. 2 illustrates only a pair of conductor segments 31, but the
conductor segments 31 are inserted into all the slots 23 of the
stator core 20.
[0027] The conductor segment 31 has a U-shape, and includes two
linear legs 31a, and a curved part 31b connecting them to each
other. When the leg 31a of the conductor segment 31 is inserted
into the space 44 of the cuff support 40 on the opposite-to-lead
side and the slot 23, the leg 31a projects axially outward from the
space 44 of the cuff support 40 on the lead side. A projecting part
of the leg 31a from the space 44 of the cuff support 40 is bent in
the circumferential direction, and welded to a leg 31a of another
conductor segment 31, as illustrated in FIG. 1. Thus, the conductor
segments 31 pass through the slots 23 and the spaces 44, so as to
form the coil 30 wound around the teeth 22 and the ribs 43. Bend
parts 32 and welded parts 33 on the lead side form the coil end 35
on the lead side. Further, the curved parts 31b of the conductor
segments 31 project axially outward from the spaces 44 of the cuff
support 40 on the opposite-to-lead side. The curved parts 31b form
the coil end 36 on the opposite-to-lead side.
[0028] As has been described earlier with reference to FIG. 3, the
ribs 43 of the cuff support 40 are warped from the roots 43a toward
the tip ends 43b so as to be apart axially outwardly from the axial
end surface 20a of the stator core 20. On this account, in a state
where the cuff support 40 is attached to the axial end surface 20a
of the stator core 20, as illustrated in FIG. 4, the annular plate
41 and the roots 43a of the ribs 43 make close contact with the
axial end surface 20a, but the ribs 43 are apart from the axial end
surface 20a from the roots 43a toward the tip ends 43b, such that a
gap between the ribs 43 and the axial end surface 20a increases
toward the inner peripheral side.
[0029] A shape of the rib 43 may be a shape inclined by a uniform
inclination from the root 43a toward the tip end 43b, or may be a
bending shape warped from the axial end surface 20a from the root
43a toward the tip end 43b. Alternatively, reversely to the above,
the rib 43 may have a shape in which an angle formed with respect
to the axial end surface 20a is larger in the root 43a, and the
angle is decreased toward the tip end 43b.
[0030] As illustrated in FIG. 2, a cuff support 40 similar to the
cuff support 40 attached to the axial end surface 20a on the lead
side is attached in a reverse manner to the axial end surface 20b
on the opposite-to-lead side of the stator core 20. Similarly to
the lead side, in a state where the cuff support 40 is attached to
the axial end surface 20b of the stator core 20 on the
opposite-to-lead side, the annular plate 41 and the roots 43a of
the ribs 43 make close contact with the axial end surface 20b, but
the ribs 43 are apart from the axial end surface 20b from the roots
43a toward the tip ends 43b, such that a gap between the ribs 43
and the axial end surface 20b increases toward the inner peripheral
side.
[0031] When the leg 31a of the conductor segment 31 is inserted
into the space 44 of the cuff support 40 on the opposite-to-lead
side and the slot 23 in a state where the cuff supports 40 are
attached to the axial end surfaces 20a, 20b of the stator core 20,
the leg 31a projects axially outward from the space 44 of the cuff
support 40 on the lead side as indicated by an alternate long and
short dash line in FIG. 4. In this state, the tip ends 43b of the
ribs 43 are apart from the axial end surface 20a.
[0032] When the leg 31a is bent in the circumferential direction as
indicated by an arrow F of FIG. 5, a side surface of the bent part
32 abuts with a surface of the rib 43 on the lead side. When the
leg 31a is further bent, the bent part 32 presses a tip end of the
rib 43, distanced from the axial end surface 20a, toward the axial
end surface 20a. Since the rib 43 is made of a resin elastic body,
the surface of the rib 43 on the lead side (an axially outer side)
is brought into pressure contact with the bent part 32 of the
conductor segment 31 due to repulsion. When the bent part 32 is
bent to a final shape, the rib 43 makes close contact with the
axial end surface 20a of the stator core 20, as illustrated in FIG.
6.
[0033] Further, when the leg 31a is bent, an inclined surface of
the curved part 31b of the conductor segment 31 on the
opposite-to-lead side abuts with a surface of the rib 43 on the
opposite-to-lead side, so that the surface of the rib 43 on the
opposite-to-lead side (an axially outer side) is brought into
pressure contact with the curved part 31b of the conductor segment
31 and the rib 43 makes close contact with the axial end surface
20b of the stator core 20.
[0034] As described above, the ribs 43 of the cuff support 40 of
the present embodiment are warped from the roots 43a toward the tip
ends 43b so as to be apart axially outwardly from the axial end
surface 20a, 20b of the stator core 20. Accordingly, when the legs
31a of the conductor segments 31 are bent in the circumferential
direction to form the coil 30, the ribs 43 are brought into
pressure contact with the coil 30 due to an elastic force. Hereby,
it is possible to improve an adhesion property between the coil 30
and the cuff support 40, thereby making it possible to sufficiently
fix the coil 30 and the cuff support 40 with varnish.
[0035] Note that, in the cuff support 40 describe above, the ribs
43 are formed in a comb shape in which the tip ends 43b on the
inner peripheral side are apart from each other, but the tip ends
43b may be connected to each other with a ring-shaped member.
[0036] With reference to FIGS. 7 to 9, the following describes a
cuff support 50 of another embodiment of the present disclosure. A
part similar to the cuff support 40 described with reference to
FIGS. 1 to 6 has a similar reference sign, and a description
thereof is omitted.
[0037] As illustrated in FIG. 7, the cuff support 50 of the present
embodiment includes a cylindrical flange 51 configured to connect
tip ends 43b of ribs 43 to each other. The annular flange 51
extends axially outward on an opposite side to an axial end surface
20a of a stator core 20 from the tip ends 43b of the ribs 43.
[0038] The cuff supports 50 as illustrated in FIG. 7 are attached
to axial end surfaces 20a, 20b of the stator core 20, and in a
similar manner to the above, conductor segments 31 are inserted
into slots 23 and legs 31a are bent in the circumferential
direction so as to form bent parts 32. Hereby, as illustrated in
FIG. 8, a surface of the rib 43 on the lead side (the axially outer
side) is brought into pressure contact with the bent parts 32 of
the conductor segments 31 and the rib 43 makes close contact with
the axial end surface 20a of the stator core 20. On the
opposite-to-lead side, a surface of the rib 43 on the
opposite-to-lead side is brought into pressure contact with
inclined surfaces of curved parts 31b of the conductor segments 31
on the opposite-to-lead side, and the rib 43 makes close contact
with the axial end surface 20b of the stator core 20.
[0039] As illustrated in FIGS. 8, 9, the flange 51 extends axially
outward in a wall shape toward an axially outer side opposite to
the axial end surface 20a of the stator core 20 from the tip ends
43b of the ribs 43 to a position of the bent parts 32 of the
conductor segments 31. This makes it possible to restrain the bent
parts 32 of the conductor segments 31 from tilting toward the inner
peripheral side. Hereby, the cuff support 50 of the present
embodiment restrains the coil 30 from protruding toward the inner
peripheral side of the stator core 20, and to restrain the coil 30
from approaching a rotor to increase a loss.
* * * * *